101601-2510 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016012510 220002390a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-2510 1016012510

HINO 220002390A 220002390a

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Cross reference number

ZEXEL 101601-2510 1016012510

HINO 220002390A 220002390a

Zexel num

Bosch num

Firm num

Name

101601-2510
101601-2512

220002390A HINO

INJECTION-PUMP ASSEMBLY
EL100 *

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 134424-0620

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 4.85 4.8 4.9

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 78.3 75.9 80.7

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.7 85.1 88.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9.7

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 100.7 98.1 103.3

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 4.9+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 6 4.5 7.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point E

Rack position 10

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 101 99.4 102.6

Fixing the rack *

Timer adjustment

Pump speed r/min 1150+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 1.9 1.4 2.4

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)RACK LIMIT
----------
DL=4-0.5mm
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Speed control lever angle

F:Full speed
----------

----------
a=11deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=18deg+-5deg b=27deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=21deg+-5deg b=69deg+-5deg

0000001501 MICRO SWITCH

Switch adjustment Adjust the bolt so that the lower lever position is obtained when the switch is turned ON. (1)Speed N1 (2)Rack position Ra
----------
N1=350+25r/min Ra=4.9mm
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Information:

Camshaft rotation counterclockwise in view shown.Firing order (injection sequence) ... 1, 5, 3, 6, 2, 4Injection timing before TC (top center):Precombustion Chamber (PC) ... 10 1°*Direct Injection (DI) ... 29 1°*Direct Injection (DI) ... 28 1°*Direct Injection (DI) ... 26.5 1°*Direct Injection (DI) ... 22.5 1°*Make reference to DI FUEL SYSTEM CHART in FUEL SYSTEM IDENTIFICATION section to find correct injection pump groups.(1) Torque for bushing ... 150 10 lb. ft.(205 14 N m)
A - 8S7167 GAUGE
B - 5P4158 GAUGE (5) Bore for the rack and diameter of the rack: Bearing at the rear (new) ... .5018 .0018 in.(12.746 0.046 mm)Bearing at the front (new) ... .5023 .0018 in.(12.758 0.046 mm)Diameter of fuel rack (new) ... .4985 .0002 in.(12.662 0.005 mm)Maximum permissible clearance between rack and bearings (worn) ... .007 in.(0.18 mm)(6) Bore in bearings for the camshaft (new) ... 2.1255 .0015 in.(53.988 0.038 mm) Diameter of bearing surfaces of the camshaft (new) ... 2.1220 .0005 in.(53.899 0.013 mm)Maximum permissible clearance between the bearings and the camshaft ... .010 in.(0.25 mm)
PRECHAMBER(9) Torque for all nuts that hold the fuel lines ... 30 5 lb. ft.(40 7 N m)(10) Torque for the nuts that hold the nozzles ... 55 5 lb. ft.(75 7 N m)(11) Body.
DIRECT INJECTION(12) Nozzle. Tighten nozzle finger tight on body (11).(13) Torque for precombustion chamber or direct injection adapter ... 150 10 lb. ft.(205 14 N m)(14) Torque for glow plug ... 120 24 lb. in.(13.6 2.8 N m)